Method of making an insulator and attaching the same to a supporting spring structure



Feb. 23, 1965 R. P. DOERER 3,170,222

METHOD OF MAKING AN INSULATOR AND ATTACHING THE SAME TO A SUPPORTING SPRING STRUCTURE Filed Jan. 28, 1963 2 Sheets-Sheet 1 1w 6 I 4 I 2% J11 w G J a i Uni FPTI/ I 4 S 41 2 Z T. a I 5 J4 BY 6/ /6 mm, Arroexvsrs as as 60 Feb. 23, 1965 R. P. DOERER 3,170,222 METHOD OF MAKING AN INSULATOR AND ATTACHING THE SAME TO A SUPPORTING SPRING STRUCTURE Filed Jan. 28, 1963 2 Sheets-Sheet 2 A WE- 34 a =45 INVENTOR. "Li-S1,; ML 44 RICA/4R0 a pols-5R 7 /6 I I 4 iw MM Mw ET: A. L

strands are internally supported by United States Patent 3,170,222 V NEH-HOD (3F iViAKllNG AN INSULATUR AND ATTAKIHING THE SAME TU'A SUPPGRTING SFRENG STRUCT Richard RDoerer, Ypsilanti, Mich, assignor to Van Dresser Specialty Corporation, Warren, Mich, a

corporation of Michigan Filed Jan. 28, 1963, Ser. No. 254,353 8 Claims. (Cl. Z9--91.1)

reinforced by a plurality of flexible strands, adapted to be attached to the supporting spring structure of an upholstered assembly.' 7

Another object is to provide a method of making an insultor of thetype having resilient reinforcing strands of undulating configuration wherein the strands are longitudinally compressed beyond their elastic limit to reduce V the overall length of said strandsto approximately the dimension of the correspondng portions of the supporting spring structure. 7

Another object is to provide a method of making an insulator wherein the strands are longitudinally compressed by the application of endwise pressure upon the ends of the strands. I

Another object isto provide a method of making an insulator Whereinthe strands are individually laterally confined during the longitudinal compression thereof Another object is to provide a method of making an insulator wherein the strands are overcompressed somewhat with respect to the dimension of the correspoding portions of the supporting spring structure so that the strands,when

relieved of pressure, will spring back more nearly to the desired length.

Another object is to provide a method of making an insulator wherein a sheet of flexible material is applied over one or both sides of the strands, either before or after the strands are compressed.

Another object is to provide a method of making an in sulator wherein'certain strands are compressed more than others. 7 7

Another object is to provide a method of makingan insulator wherein the strands are of helical configuration.

Another object is to provide a method of making an insulator wherein the endmost convolutions of the helical pilots during compression. I

Other objects, advantages and novel details of construction of the invention will be made more apparent as this description proceeds, especially when considered in connection with the accompanying, drawings, wherein:

'FIGURE 1 is a perspective view of an upholstered ass'embly provided with an insulator constructed in accordance with this invention, and showing parts broken away and in section.

FIGURE 2 is a top plan view of the core of the insulator before the strands are compressed, shownoverlying the border'frame of the supporting spring structure of the upholstered assembly. I

FIGURE} is a top plan view of a compression fixture forcompressing the strands of the core, showing the core in position between the closed plates of thefixture, with parts broken away.

FIGURE 4 isan end view of the fixture shown in between the closed plates.

3,170,222 Patented Feb. 23, 1965 ice core. v

FIGURE 5 is a side view of the fixture, showing the core FIGURE 6 is an enlarged fragmentary sectional view showing a piston extending into one of the grooves of the compression fixture. V

FIGURE 7 is a plan view of the insulator core, after it 1 has been compressed, shown over the border frame to ilterial.

lustrate the configuration of the compressed core with respect to that of the border frame.

FIGURE 8 is a plan View of the complete insulator shown marginally attached to the border frame of the supporting spring structure,the dotted lines indicatingthe outline of the insulator prior to being marginally attached to theborder frame.

FIGURE 9 is a semi-diagrammatic view taken on line,

9-9 of FIGURE 8.

FIGURE 10 is a semi-diagrammatic view taken on the line 1tiitl of FIGURE 8; omitting the border frame.

FIGURE 11 is, an enlarged sectional view of a portion of FIGURE 10.

FIGURE 12 is a fragmentary view of a modified form of the insulator before the strands have been compressed.

FIGURE 13 is a fragmentary view of the modified insulator after the strands have been compressed and the insulator isready for use.

I FIGURE 14 illustrates a step in the manufacture of the modified insulator. e v In the drawings, A is an elongated, substantially'horizontal, flexible, bodily stretchable, sheet-like insulator embodying my invention disposed between an overlying padding B for an exterior trim material C and an underlying supporting spring structure D of an upholstered assembly. The insulator A is best shown in FIGURES 8-11 and includes an elongated sheet of flexible material 10, another elongated sheet of flexible material 12 having substantially the same marginal outline as the sheet 10, and a pre-compressed reinforcing core 14 between the sheets 19 and 12. The insulator is a composite laminated structure with the core 14 constituting a lamination or layer between the outer layers or sheets 10 and 12 of flexible ma The rare-compressed core 14 includes a plurality of laterally spaced, substantially parallel, resilient stretchable reinforcing strands is. The core is best seen in FIGURE 7 and it will be noted that anchorage means or members which may be in the form of cords 18 extend along both ends of the core 1 to which the wire strands are terminally connected. The ends of the wire strands maybe simply wrapped or folded around the cords and held in a predetermined spaced relation to one another. The strands between their ends are helical as is apparent.

The supporting spring structure D includes an elongated substantially horizontal border frame 2% having the conframe. The outline of the insulator A is shown in dotted lines in FIGURE 8. Preferably, the sheets llland 12 are slightly larger both in width and length than the border frame, while the core is very close in outline to that of the border frame. v

As seen particularly in FIGURES 9 and 10, the sheet 12 is substantially fiat and the sheet 10 is formed with loops 36 extending substantially from one end to the other, which cooperate with the sheet 12 in defining parallel open tunnels or pockets 32 which extend lengthwise of the insulator. The sheets are secured together by staples 33 or any other suitable securing means such, for example, as

stitching or adhesive. In this instance the staples run between the pockets 32 to separate them from each other. A strand 16 is disposed in each of the pockets 32, and the cords or anchorage members 18 extend across the ends of the pockets. It will, of course, be understood that the strands may, if desired, extend crosswise rather than lengthwise of the insulator.

Preferably the sheets are pleated transversely of the pockets, that is the material of the sheets is formed to provide the pleats 34 which extend at right angles to the pockets from one side to the other. The pleats are shown in FIGURE 11. By thus pleating the sheets, the sheets, as well as the strands 16, are stretchable in the direction of length of the insulator so as to yield under load.

The insulator is shown in FIGURE 8 marginally secured to the border frame 20, as by means of hog rings 35. The hog rings encircle the border frame and at the ends of the insulator also encircle the anchorage members or cords. The hog rings of course pierce the sheets. Other securing means such, for example, as clips may be provided instead of hog rings.

Although the various elements of the insulator may be formed from any suitable material for the purposes set forth, the sheets 10 and 12 are preferably formed of burlap, and the reinforcing strands 16 are preferably formed of wire. The anchorage members or cords 18 may be formed for example of rolled or folded burlap.

In the manufacture of the insulator shown in FIGURES 8ll, the core 14 is first formed to the shape and configuration shown in FIGURE 2. The core in its initial form shown in FIGURE 2 is designated 14', and it will be noted that the strands 16 are all initially of the same length and that the pitch of the helical convolutions is also the same. The ends of the strands are terminally connected to the anchorage members or cords 18 by being folded or wrapped about the cords, and the core thus formed is substantially rectangular with the strands substantially parallel and in laterally spaced relation to each other.

The core 14' of FIGURE 2, which is there shown in its free state, must be formed to the shape shown in FIGURE 7 before it is ready to be assembled with the sheets 10 and 12 to complete the composite insulator A. In other words, the strands 16 must be longitudinally compressed, certain strands more than others, so that in the free state of the core it assumes substantially the outline shown in FIG- URE 7 which corresponds closely to the outline of the border frame. To accomplish this, the fixture 36 shown in FIGURES 3-6 is employed. The fixture 36 has a base 38 and a lower plate 40 supported on the base by posts 42. An upper plate 44 is supported for vertical reciprocation above the lower plate 40. The upper plate 44 is guided in its reciprocation by pins 46 and is positively moved by any suitable means such as the hydraulic cylinder 48.

The lower plate 40 is formed in its upper surface with a plurality of laterally spaced, parallel semicylindrical grooves 50, and the upper plate 44 is formed in its lower surface with a like series of parallel semicylindrical grooves 52. When the plates are brought together, the grooves register with one another to define cylindrical passages 54 open at both ends of the plates.

As shown in FIGURES 3 and 4, a series of plungers 56 is provided at each end of the fixture, the plungers respectively being aligned with the adjacent ends of the cylindrical passages 54. In other words, there is one plunger for each end of each passage, and the plungers are guided for reciprocation along the axes of the respective passages. For this purpose, any suitable means may be employed. The plungers are of course individually operated so that some may reciprocate through a larger stroke than others. The plungers have reduced ends 55 adapted to extend into the end convolutions of the strands to serve as pilots during compression, the end convolutions bearing against the annular shoulders l 59 defined by the reduced ends 55 (see FIG. 6).

While preferably two plungers are provided for compressing each strand, only one need be employed. That is, one plunger may be provided to engage one end of the strand and a fixed abutment may be provided for the opposite end.

In operation, the plates 40 and 44 of the fixture 36 are separated and the insulator core 14' in its initial condition shown in FIGURE 2 is laid over the lower plate with the strands 16 in the respective grooves 50. The upper plate 44 is then lowered or clOsed with respect to the lower plate 40, as shown in FIGURES 4 and 5, thereby confining the strands in the respective passages 54. Although the strands are closely confined in t passages, they are capable of movement in an axial drrection. The plungers 56 are advanced into the passages 54, engaging the ends of the strands and compressingthem axially, thereby closing the pitch of the convolu tions of the helix. In this connection, it will be noted in FIGURESA and 5 that the opposed surfaces of the plates 40 and 44 are relieved or cut away near both ends, as shown at 61, for some distance toward the middle in order to clear the anchorage members or cords 18.

The strands 16 are compressed far enough to exceed their elastic limit so that when the plungers 56 are withdrawn the strands will not return to their original full length shown in FIGURE 2. The dotted positions 57 (FIG. 3) of cords 18 indicate the extent to which the strands are compressed. When the plungers are Withdrawn, the strands spring back slightly and assume a permanent free state condition indicated by the positions 58 of cords 18. The fixture 36 is then opened and t ore-compressed core 14 removed for assembly with t sheets 10 and 12 to form the composite insulator V The sheets 10 and 12 when laid out flat areslightly longer than illustrated in dotted lines in FIGURES 8 and 10, it being understood that in these figures the fna= terial of the sheets has been transversely pleated as indi= cated in FIGURE 11 at 34, somewhat shortening their overall length. It will also be understood that when laid fiat the sheet 10 is of a somewhat greater dimension from side to side than the sheet 12 since enough material must be provided to form the loops 30. p

In order to form the composite insulator A from its parts, the pre-compressed core 14 shown in FIGURE 7 may be laid over the sheet 12 the sheet 12 having first been pleated in a transverse direction. The sheet 10 may then be laid over the core and likewise transversely pleated. The margins of the sheets coincide with one another, and the material of the upper sheet 16 Frill fold about the individual strands 16 to form the loops 30. The sheets are secured together by any suitable means such as the staples 33 which run between the loops 30 to permanently separate the pockets or tunnels 32 from each other. The completed insulator A is attached to the border frame by any suitable means such as the hog rings 35. When laid over the border frame in its free state, the margins of the sheets are as shown in dotted lines in FIGURE 8. The margins of the sheets are folded over the border frame, in the manner shown in FIGURE 9, and the hog rings are applied without the need of any stretching. The hog rings encircle the border frame and also the cords 18 which lie inside the ends of the border frame.

FIGURE 12 illustrates one end of a modified insulator A before the strands have been compressed. It will be, understood that the opposite end of the insulator A before compression will be a mirror image of that shown in FIGURE 12. FIGURE 13 illustrates the opposite end of the same insulator A after the strands have been compressed and the insulator is ready for use. The other end of the insulator A after compression is a.- mirror image of the FIGURE 13 illustration. The insulator A differs from the insulator A. in. the initialconfiguration of the sheets 1% and 12' and in the method of manufacture.

The core 14 of insulator A is the same as the core of insulator A, but the sheets of flexible material and 12 differ in that theyare initially rectangular. The sheets 10 and 127 are initially somewhat longer and wider than the core and, cover opposite sides of the core, 50 that the core formsa lamination between the sheets. In this form of the invention, the sheets 10 and 12 are secured together on'opposite sides of the core before, rather than after, the core is compressed. The core is I shown in FIGURE 12 prior to compression of the strands 16 and is there designated 14. The staples 33-secur'e the sheets'together'in the spaces between the strands 16, thus providing the tunnels 32 for the indlvidual strands.

Theinsulator as it is shown in FIGURE 12 1s structurally complete but has not been compressed. It -1s placed between two plates 40 and 44 of the compression fixture 36 so that the strands of the core registenwith the matching grooves 50 and 52 of the fixture. Thls can be seen in FIGURE 14. When the upper plate 44 is brought down on the lower plate 40, the strands 16 will be laterally confinedwithin the passages 54 defined by the matchlng grooves, whereupon the pistons56 are advaneedimto the passages 54 to compress the strands beyond their elastic limit as beforedescribed in connection with the manufacture of insulator A. The plates of the fixture should not be moved as closetogether as they were in the manufacture of insulator A,'because of the presence of the sheets 1t) and 12. If desired, the sheets along their ends may be spread apart so th-at'the pistons 56 can enter the tunnels 32be'tween the sheets and engage the ends of the strands The reduced ends of the pistons will enter the end-convolutions of the strands to act as pilots, as

before described in connection with'the manufacture of insulator A;

The finished insulator A, one-end of which is shown in FIGURE 13, will have substantially the same outline as the insulator A shown in'FIGURE. 8. The sheets of the insulator A will betransverselypleated in the cornpres'sion fixture by the action of the pistons 56. These pleats extend from one side of the insulator to the other generally transversely of the strands, although near the side where the strands are compressed to a greater degree (i.e., the bottom side in FIGURE 13) lthepleats are of course somewhat deeper. Moreover,'the curved portions 65 of the endsof the insulator A are somewhat irregular in outline due-to, the fact that the sheets are initially rectangular. Except in the particulars mentioned, in-. sulator A is the sarne as insulator A. The insulator A v is attached to the'border frame by any suitable means i such as hog rings 35 in exactly the same manner 3 .5 the insulator A described above. C

Both insulatorA and A are capable of stretching longi tudinally, since the pie-compressed strands of the cores. are stretchable and the pleated material of the sheets is u likewise capable of extending or stretching;

Although the strands are shown extending from end to end of insulators A and A, they may extend transversely,

that is from side to side, in which event the pleatswould extend from end to end.-'

While the strands 16 are preferablyhelical as shown, they mayalso'be" of other undulating form. Thus the undulations may, for example, lie in the sam'eplaneandbe sinuous, or V-shaped, or any otherdesiredwavy configuration. I? a What I claim as my invention-is:

1.'"A method of forming an elongated, flexible, sheet- 7 like insulator having inits free state condition a' lengthwise dimension approximating the lengthwise dimension of an'elon'gated border frame of a supporting spring 7 structure of an upholstered assembly, 'for use of'said insulator between said supporting springstructure and an overlying padding; comprising providing first and 'secondelongated sheet of flexible material adaptedto extend lengthwise of said border frame and which have a lengthwise dimension approximating the lengthwise dimensionof said border frame, providing a plurality of elongated, laterally spaced, substantially parallel, flexible, resilient reinforcing strands of undulating form adapted to extend lengthwise of said border frame and which are initially longer than the corresponding portions of'said border frame, longitudinally compressing said strands beyond wise'dimensio'n approximating the lengthwise dimension' of an elongated border frame of 'aisupporting spring structure of an upholstered assembly, for use of said insulator between said supporting spring structure and an overlying padding; comprising providing first and second elongated flat sheets of flexible material adapted to extend lengthwise of said border frame and which are longer than said border fframe, providing a plurality of elongated, laterally spaced, substantially parallel, flexible, resilient, helical reinforcing strands adapted to extend :lengthwiseof saidborder frame and which are initially longer than the corresponding portions of said border frame, forming transverse undulations in said sheets to shorten the same to an overall length approximating the lengthwise dimension of said borderframe,ilaterally confining said strands, longitudinallycompressing the strands beyond their elastic limit by applying endwise pressure upon thegends of said stra'ndswhile they fare compressed and then relieving said strands of the endwise pressure and confinement so that'said strands assume' a stable free state condition of decreased length and have approximately the same lengthwise dimension respectively as the A corresponding portions of said border frame, then extend 7 ing said compressed strands upon one side of said first shortened sheet lengthwise thereof and extending said second shortened sheet uponthe side of said compressed strands opposite said first sheet lengthwise of said first sheet, then forming longitudinally extending portions of said sheets to provideindividual tunnels for the separate strands, and thereafter securing said sheets together between said respective strands to confine said strands within said tunnels and. to maintain the substantially parallel relation of said strands.

3. The methoddefined in claim 2, wherein said strands are shortened by the aforesaid application of endwise i pressure upon the ends thereof to:lengths less than the corresponding portions of said border frame so that when Isaid strands are'relieved of said endwise pressure they spring back to an overall length more nearly approximating the lengthwise dimensionof the corresponding portions of said border frame.

4. Themethod defined inclaim 3, wherein anchorage members are provided along opposite ends of said strands,

to which said' strands are. terminally connected prior to I being compressed, and attaching said anchoragernernbers to the ends of said border frame after said sheets are,

secured together as aforesaid.

5, A method offorminganelongated, flexiblej sheet like insulator having in its free state condition a lengthr wise dimension approximating the lengthwise dimen-- 'sion of an elongated border frameof a supporting spring structure of an upholstered assembly, for use v of said insulator between said supporting spring struc-' ture and an overlying padding; comprising providing first and second elongated flat sheets of flexible-material adapted to extend lengthwise of said border frame and which are longer than said border frame, providing a plurality of elongated, laterally spaced, substantially parallel, flexible, resilient, reinforcing strands of undulating form adapted to extend lengthwise of said border frame and which are initially longer than the corresponding portions of said border frame, extending said strands upon one side of said first flat sheet lengthwise thereof and extending said second flat sheet upon the side of said strands opposite said first fiat sheet lengthwise of the latter, then securing said sheets together, then forming transverse undulations in said sheets to shorten the same to an overall length approximating the lengthwise dimension of said border frame while simultaneously longitudinally compressing said strands to a stable free state condition of decreased length such that said compressed strands have approximately the same lengthwise dimension respectively as the corresponding portions of said border frame.

6. A method of forming an elongated, flexible, sheetlike insulator having in its free state condition a lengthwise dimension approximating the lengthwise dimension of an elongated border frame of a supporting spring structure of an upholstered assembly, for use of said insulator between said supporting spring structure and an overlying padding; comprising providing first and second elongated flat sheets of flexible material adapted to extend lengthwise of said border frame and which are longer than said border frame, providing a plurality of elongated, laterally spaced, substantially parallel, flexible, resilient, helical, reinforcing strands adapted to extend lengthwise of said border frame and which are initially longer than the corresponding portions of said border frame, extending said strands upon one side of said first flat sheet lengthwise thereof and extending said second fiat sheet upon the side of said strands opposite said first flat sheet lengthwise of the latter, then forming longitudinally extending portions of said sheets to provide individual tunnels for the separate strands, then securing ;said sheets together between said respective strands to confine said strands within said tunnels and to maintain the substantial parallel relation of said strands, then laterally confining said sheets and strands, then while said sheets and strands are confined forming transverse undulations in said sheets to shorten the same to an overall length approximating the lengthwise dimension of said border frame while simultaneously compressing said strands beyond their elastic limit by applying endwise pressure upon the ends of said strands and then relieving said strands of the endwise pressure so that said strands assume a stable free state condition of decreased length and have approximately the same lengthwise dimension respectively as the corresponding portions of said border frame.

7. The method defined in claim 6, wherein said strands are shortened by the aforesaid application of endwise pressure upon the ends thereof to lengths less than the corresponding portions of said border frame so that when said strands are relieved of said endwise pressure they spring back to an overall length more nearly approximating the lengthwise dimension of the corresponding portions of said border frame.

sheets as aforesaid and said strands have been compressed as aforesaid.

References Cited by the Examiner UNITED STATES PATENTS 2,218,708 10/40 Haberstump 155179 2,283,116 5/42 Young 155179 3,010,195 11/61 Richards 29-419 3,017,698 1/62 Hambrecht et a1 294l9 .WHITMORE A. WILTZ, Primary Examiner.

THOMAS H. EAGER, Examiner. 

1. A METHOD OF FORMING AN ELONGATED, FLEXIBLE, SHEETLIKE INSULATOR HAVING IN ITS FREE STATE CONDITION A LENGTHWISE DIMENSION APPROXIMATING THE LENGTHWISE DIMENSION OF AN ELONGATED BORDER FRAME OF A SUPPORTING SPRING STRUCTURE OF AN UPHOLSTERED ASSEMBLY, FOR THE USE OF SAID INSULATOR BETWEEN SAID SUPPORTING SPRING STRUCTURE AND AN OVERLYING PADDING; COMPRISING PROVIDING FIRST AND SECOND ELONGATED SHEET OF FLEXIBLE MATERIAL ADAPTED TO EXTEND LENGTHWISE OF SAID BORDER FRAME AND WHICH HAVE A LENGTHWISE DIMENSION APPROXIMATING THE LENGTHWISE DIMENSION OF SAID BORDER FRAME, PROVIDING A PLURALITY OF ELONGATED, LATERALLY SPACED, SUBSTANTIALLY PARALLEL, FLEXIBLE, RESILIENT REINFORCING STRANDS OF UNDULATING FORM ADAPTED TO EXTEND LENGTHWISE OF SAID BORDER FRAME AND WHICH ARE INITIALLY LONGER THAN THE CORRESPONDING PORTIONS OF SAID BORDER FRAME, LONGITUDINALLY COMPRESSING SAID STRANDS BEYOND THEIR ELASTIC LIMIT TO A STABLE FREE STATE CONDITION OF DECREASED LENGTH SUCH THAT SAID COMPRESSED STRANDS HAVE APPROXIMATELY THE SAME LENGTHWISE DIMENSION RESPECTRIVELY AS THE CORRESPONDING PORTIONS OF SAID BORDER FRAME, EXTENDING SAID COMPRESSED STRANDS UPON ONE SIDE OF SAID FIRST SHEET LENGTHWISE THEREOF AND EXTENDING SAID SECOND SHEET UPON THE SIDE OF SAID COMPRESSED STRANDS OPPOSITE SAID FIRST SHEET LENGTHWISE OF SAID FIRST SHEET, AND THEN SECURING SAID SHEETS TOGETHER. 